Forehead support for facial mask

ABSTRACT

The present invention discloses an adjustable forehead support for a nasal or full-face mask wherein the forehead support may be adjusted for the different shapes and sizes of a facial profile. The forehead support utilizes a dual-arm system that adjusts the position of the forehead support vis-á-vis the mask and/or airflow tube. The angle of the mask to the face may be adjusted with the present invention.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to an improved comfort device tobe used with a nasal mask. In particular, the device is useful incombination with masks which are used for the treatment of respiratoryconditions and assisted respiration. The invention assists in fittingthe mask to the face as well.

2. General Background

Nasal masks are commonly used in the treatment of respiratory conditionsand sleep disorders by delivering a flow of breathable gas to a patientto either assist the patient in respiration or to provide a therapeuticform of gas to the patient to treat sleep disorders such as obstructivesleep apnea. These nasal masks typically receive a gas through a supplyline which delivers gas into a chamber formed by walls of the mask. Themask is generally a semi-rigid mask which has a face portion whichcovers at least the wearer's nostrils. Additionally, the mask may be afull face mask. The mask is normally secured to the wearer's head bystraps. The straps are adjusted to pull the mask against the face withsufficient force to achieve a gas tight seal between the mask and thewearer's face. Gas is thus delivered to the mask and the wearer's nasalpassages and/or mouth.

One of the problems that arises with the use of the mask is that inorder for the straps to be tight, the mask is compressed against thewearer's face and may push unduly hard on the wearer's nose.Additionally, the mask may move around on the wearer's face. Thus, therehas been provided a forehead support, which provides a support mechanismbetween the mask and the forehead. This forehead support prevents boththe mask from pushing too strongly against the wearer's nose and/orfacial region as well as minimize movement of the mask with the additionof a contact point between the mask and the wearer's head as well asminimize uncomfortable pressure points of the mask. Additionally, theforehead support may prevent the airflow tube from contacting thewearer's forehead or face.

FIG. 1 shows a general perspective view of a related art foreheadsupport 10. The forehead rest or support 10 is attached to an airflowtube 12 extending from the mask 14. The mask 14 and forehead support 10are shown with headgear 16 which secures the mask 14 to the head of apatient. As can be seen in FIG. 1, the headgear 16 loops through theforehead support 10 at loops 18 and 20. This pulls the forehead support10 against the forehead, thus creating a snugly fitted mask 14 and alsoprovides a stabilizing member for the mask 14.

FIG. 2 discloses the construction of the related art forehead support10. The forehead support 10 has pads 24 and 26, a back side of which canbe seen in greater detail in FIG. 10. These pads 24 and 26 are theactual contact points of the forehead support 10 to the forehead. Thesupport pads 24 and 26 are mounted to the bridge 32. Arms 34 and 36 aresecured to bridge 32 by an adjustable locking mechanism which is betterillustrated in the figures below. The bridge 32 provides three purposesto the forehead support 10. First, it acts as a securing means for pads24 and 26. Second, it has loops 18 and 20 which receive the optionalheadgear 16 shown in FIG. 1. Finally, it receives arms 34 and 36, whichmay be adjusted, as described below. The bridge 32 and arms 34 and 36operate in a cantilever fashion and are made of a polymeric material,which may be easily molded. Additionally, arms 34 and 36 join togetherto create an annular space 38 to receive airflow tube 12 which isconnected to a flow generator to generate breathable air or some type oftherapeutic gas. Arms 34 and 36 create an operational hinge. The tube 12is an axis of this hinge.

FIG. 3 is an exploded view of FIG. 2 and shows the forehead support 10in greater detail. Bridge engaging pins 56, 58, 60 and 62 are shown inFIG. 3. As will be more apparent in the figures below, these engagingpins provide for the adjustability of the forehead support 10. Bridge 32includes slots 76, 78, 82, 84, 86, 88 and 90 (see FIG. 9) and a mirrorset of slots on the upper portion of bridge 32 (not visible in FIG. 9)for selectively receiving pins 56, 58, 60 and 62. These slots open tothe forehead side of the bridge. Additionally, there is a space orrecess at arms 34 and 36 shown on arm 34 as 64. The purpose of thisspace 64 is so that the user may compress arm 34 and thus press pins 56and 58 together by pressing on surfaces 66 and 68. The purpose of thecompression is to decrease the distance between pins 56 and 58 such thatthey may be selectively inserted and locked into the desired pair ofslots on bridge 32. The length of the pins 56 and 58 is such that evenwhen the pins are pressed together, they do not clear the slots in thebridge sufficiently to allow the arms to be disassembled from the bridgewithout further action.

FIG. 4 is a side view of the mask 14 and forehead support 10. The maskis shown as 14 with a dotted line showing the nose of a wearer 70 andthe dotted line showing the forehead 72 of the wearer. Pad 26 is showncompressed by the forehead of the individual wearing the mask.

FIG. 5 is a top view of the forehead support 10 taken along lines 5 ofFIG. 4. Also, the mask 14 is not shown in FIG. 5. This figureillustrates the forehead support 10 in a position wherein the foreheadsupport is in the closest position to the tube 12 (shown as merely aspace in FIGS. 5-6). The bridge 32 is shown essentially in contact withtube 12. The pins 56, 58, 60 and 62 are shown in their furthest positionfrom the center of the bridge 32, engaging slot pairs 88 and 90. Thisposition may be utilized by someone with a large, protruding or bulbousforehead, or a high nasal bridge, or someone who prefers the airflowtube to be snug against their forehead. FIG. 6 shows the same foreheadsupport in the next position, wherein the bridge 32 is moved away fromtube 12 such that there is a gap 74 between bridge 32 and tube 12. Here,pins 56, 58, 60 and 62 engage slot pairs 76 and 86. As is visible fromthe figure, the forehead support 10 is now moved away from tube 12, andis positioned differently than in FIG. 5. This may be configured to fitsomeone with a less protruding forehead, or someone who wants theflexible tube further from their head than is possible in FIG. 5. FIGS.7 and 8 show the third and fourth position for the forehead support.

The related art arm 34 is shown in greater detail in FIGS. 11-13. As canbe seen in the top view of the arm 34 shown in FIG. 11, the arm 34includes a semicircular portion 100, on an interior of which the annularspace 38 is situated. An extending portion 102 extends from thesemicircular portion 100. Surfaces 66 and 68, space 64 and engaging pins56 and 58 are positioned on the extending portion 102. Each surface 66and 68 includes a generally oval depression 106 and 108, respectively,positioned near the pins 56 and 58. These oval depressions 106 and 108can be felt by the wearer of the mask and assist the wearer in properlypositioning his or her fingers near the pins 56 and 58 when it isdesired to adjust the forehead support. This is especially importantwhen the mask and forehead support are positioned on the wearer's headbecause at such time, the wearer cannot easily see where to place his orher fingers to adjust the forehead support. The oval depressions notonly assist the wearer in properly positioning his or her fingers foradjusting the support, by virtue of the fingers engaging thedepressions, the depressions also help maintain the fingers in theappropriate position.

FIG. 12 is a side view of the arm shown in FIG. 11. As can be seenthere, the semicircular portion 100 only extends upward to half of theheight of the arm 34. Because of this, the arm 34 is reversible, i.e.,it can be flipped over, and then can be used as arm 36. Thus, only onearm design need be molded and this can be used as both arm 34 and arm36, depending on its orientation. Extending portion 102 includes twohorizontal flanges 110 and 112 connected by an intermediate web 114. Thetwo horizontal flanges are thicker in the horizontal direction andthinner in the vertical direction than web 114. The space 64 ispositioned on web 114. The force required to press the pins 56 and 58together is a function of the amount of material of the extendingportion 102 on either side of the space 64 in the vertical direction,the length space 64 extends along portion 102 (i.e., the length of eachcantilever arm on either side of space 64) and the type of material fromwhich the arm 34 is constructed. These arms have been constructed of apolycarbonate, specifically, Makrolon 2458 manufactured by Bayer.

FIG. 13 shows a cross-section of the arm 34 along line 13-13 in FIG. 12.The comparative thicknesses of the flange 112 and the web 114 in thehorizontal direction can best be seen here. The hatched portion of thearm 34 is the portion of the web 114 beyond the extended length of thespace 64.

It has been found that while the related art forehead support performscorrectly if operated according to the instructions, an improvement canbe made to reduce the risk of breakage when the forehead support isoperated in a manner contrary to instructions.

Further, because depressions 106 and 108 are relatively narrow, animprovement can be made to allow the user to positively and firmlyposition his or her fingers to press the pins 56 and 58 together.Finally, because there is a relatively large amount of material contactbetween an interior of semicircular portion 100 and an exterior ofairflow tube 12, this can result in a relatively large amount offriction between the arm 34 and the tube 12, thereby requiringadditional force to pivot the arm 34 around the tube 12 for adjustmentpurposes.

SUMMARY OF THE INVENTION

The present invention is directed to an improved version of the type offorehead support discussed above. In particular, the present inventionutilizes improved arms extending from the mask or gas supply line foradjustably engaging the bridge for allowing positioning of the mask onthe face. First, extending portions of the arms are redesigned tocompress more easily than the extending portions of the related art armsdiscussed above while at the same time maintaining the strengthnecessary for adequately supporting the airflow tube. Thus, the engagingpins may more easily be compressed together to allow for adjustment ofthe arms with respect to the bridge.

Furthermore, the extending portions of the arms are provided withlocking portions that maintain alignment of the pins with respect to oneanother as they are being compressed to prevent lateral deflection ofthe pins, unintended stress loading on the arms and to allow easierengagement of the pins with the slots upon release of the extendingportions.

Finally, arc portions of the arms that come into contact with theairflow tube 12 are undercut and radiused to prevent sticking or bindingof the arms as they are pivoted about the airflow tube during adjustmentof the forehead support, as compared to the related arm embodiment.Thus, the arms more easily pivot about the airflow rube duringadjustment of the forehead support.

These improvements make it easier to adjust the forehead support, aswell as make it easier to disassemble the arms from the bridge to allowthorough cleaning of the bridge and other support components.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a related art forehead support attachedto a mask, headgear and a gas supply tube;

FIG. 2 is a perspective view of the forehead support of FIG. 1 removedfrom the mask and gas line;

FIG. 3 is an exploded view of the forehead support of FIG. 1;

FIG. 4 is a side view of the forehead support of FIG. 1 secured to amask;

FIG. 5 is a top view of the forehead support of FIG. 1 in a firstposition;

FIG. 6 is a top view of the forehead support of FIG. 1 in a secondposition;

FIG. 7 is a top view of the forehead support of FIG. 1 in a thirdposition;

FIG. 8 is a top view of the forehead support of FIG. 1 in a fourthposition;

FIG. 9 is a front view of a bridge of the support of FIG. 1;

FIG. 10 is a single pad of the support of FIG. 1;

FIG. 11 is a top view of a of an arm for use in the forehead support ofFIG. 2;

FIG. 12 is a side view of the arm of FIG. 11;

FIG. 13 is a section view of the arm of FIG. 12 along section line13-13;

FIG. 14 is a top view of an improved arm for use in the forehead supportof FIG. 2;

FIG. 15 is a side view of the arm of FIG. 14;

FIG. 16 is a section view of the arm of FIG. 15 along section line16-16;

FIG. 17 is a perspective view of the arm of FIG. 11;

FIG. 18 is a partial section view of the arm of FIG. 13 along sectionline 18-18;

FIG. 19 is a partial section view of the arm of FIG. 15 along sectionline 19-19; and

FIG. 20 is a partial section view of the arm of FIG. 15 along sectionline 19-19.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 14 shows a top view of an improved embodiment of an arm for usewith the present invention. Arm 200 includes a semicircular portion 202and an extending portion 204 attached thereto. Semicircular portion 202includes two arc portions 230 and 232 and an inner bore 234. The two arcportions 230 and 232 are both recessed or undercut near their ends, asshown by the phantom lines 236 and 238. Thus, the inner bore 234 is notperfectly circular in shape near the ends of arc portions 230 and 232.Ends 240 and 242 of the arc portions 230 and 232, respectively, are wellradiused to prevent binding of the arm on the airflow tube duringpivoting.

Extending portion 204 includes two flange portions 206 and 208 on whichgenerally oval depressions 210 and 212 are respectively positioned.Bridge engagement pins 214 and 216 are positioned at far ends of flangeportions 206 and 208, respectively, and project, respectively, upwardlyand downwardly from the arm 200. A space 218 separates the flangeportions 206 and 208 and in this embodiment, it can be seen that thereis no vertical web between the respective flange portions and the space218. Also, it can be seen that the space 218 extends along a greaterportion of arm 200 than does the embodiment shown in FIG. 12. Thus, thecantilever arm portions of the arm of FIG. 14 are longer than thecantilever arm portions of the arm of FIG. 2. Further, the cantileverarm portions of the arm of FIG. 14 are tapered along their length, suchthat the thickness of these portions is less near the pins than thesemicircular portion 202. Compare the thicker section of the arm of FIG.15 shown in FIG. 19 with the thinner section of the arm taken nearer thepin 214 shown in FIG. 20.

Even though the thickness of the cantilever arm portions of the arm ofFIG. 15 have been reduced as compared to the arm of FIG. 2, the width ofthese portions has been increased with respect to the arm of FIG. 2.Compare the widths of the arm of FIG. 15 shown in FIGS. 19 and 20 withthe width of the arm of FIG. 13 shown in FIG. 18. The increased width ofthe improved arm of FIG. 15 provides a stiffness in the lateral planethat is about 8 times greater than the stiffness of the arm of FIG. 2.This increased stiffness prevents most accidental lateral deflections ofthe pins and would likely require a determined intentional action tolaterally deflect the cantilever arm portions and pins.

A male locking portion 220 is positioned inboard of pin 214 and a femalelocking portion 222 is correspondingly positioned inboard of pin 216.The male and female locking portions are configured so as to be able tofittingly mate with one another when the two flanges portions 206 and208 are pressed together. As seen in FIG. 16, a section along line 16-16in FIG. 15, the female locking portion can be configured as achevron-shaped slot Correspondingly, the male locking portion 220 wouldbe configured as a chevron-shaped projection to mate with thechevron-shaped slot of female locking portion 222. The male and femalelocking portions can also have different shapes, as long as they willlockingly mate together when the two flange portions are pressedtogether. As with the arm 34 above, the arm 200 can be flipped over toprovide the second arm of the forehead support and thus, only one moldis needed to cast both required arms.

The lengths of the pins 214 and 216 are provided such that when the pinsare pressed together to the extent allowed by the locking portions, thepins will clear the slots in the bridge, contrary to the pins of therelated art arms.

In a preferred embodiment, these improved arms are constructed of apolycarbonate, specifically, Makrolon 2858 manufactured by Bayer.

There are several advantages to this improved arm embodiment. First,because the space 218 extends farther along the arm 200, the lack of aweb between the flanges 206 and 208 and the tapering of the cantileverarm portions, it is as easy or easier to press the pins 214 and 216together when adjusting the forehead support, even with the increasedlateral strength of the improved arms. This is especially importantbecause during the adjustment while the mask is on the wearer's head,the wearer cannot easily see the forehead support as he or she isperforming the adjustment. The increased lateral strength helps resistaccidental lateral deflection of the cantilever arm portions and pins,as well as providing a stronger support to the airflow tube. The endresult is that at the outer portion of the arm 200 near the pins, theextending portion 204 has a greater stiffness and resistance to bendingin the lateral or horizontal direction (i.e., the pivoting direction)than it does in the vertical direction (the non-pivoting direction).This is contrary to the embodiment shown in FIGS. 11-13 where thestiffness and resistance to bending is greater in the vertical directionthan in the horizontal direction.

Of course, the taper, shape and/or the thickness of the cantilevered armportions can be altered to vary the stiffness of the cantilevered armportions in the horizontal or vertical directions, as circumstanceswarrant. Further, under certain circumstances, it is contemplated thatthe stiffness of the cantilevered arm portions in the vertical directioncan be less, similar to, or even greater than the comparable stiffnessof the cantilevered arm portions of the related art design in thevertical direction.

The use of the wider flanges also allows the use of broader ovaldepressions 210 and 212. These broader depressions better accommodatethe wearer's fingers and thus, give the wearer a more positive and morecomfortable grip on the arms during adjustment.

The provision of the male and female locking portions assures that thetwo flange portions remained aligned with one another during thepressing together of the pins 214 and 216. Thus, the pins are alsomaintained in alignment during compression, making it easier for bothpins to align with their respective slots in the bridge duringadjustment of the bridge. Without the locking mechanism, the pins can betwisted and splayed with respect to another during compression, makingit more difficult to position the pins in the desired respective slotsin the bridge during adjustment. Further, the locking portions alsoprevent the user from laterally deflecting the pins with respect to oneanother when disassembling the arm from the bridge. Since the pins areshort enough to clear the slots in the bridge when pressed together, thearm need not be rotated or the pins laterally displaced from one anotherto allow the pins to clear the slots in the bridge. This reduces thatthe chance that a user can operate the arms contrary to instructions andthereby place undue stresses on the arms that could lead to prematurefailure of the arms.

Finally, the provision of the undercut or recessed portions 236 and 238on arc portions 230 and 232 reduces the amount of material of the armthat comes into contact with the airflow tube 12 (or other pivot point).This helps prevent sticking or binding of the arm as it is pivoted aboutthe airflow tube during adjustment of the forehead support, as comparedto the related arm embodiment. The radiused ends 240 and 242 are alsoless likely to catch and hang up on imperfections in the airflow tubeduring pivoting, as compared to the sharper ends of the related armembodiment. Thus, the arm 200 more easily pivots about the airflow tubeduring adjustment of the forehead support.

These improvements in arm 200 thus make it easier to adjust the foreheadsupport, as well as make it easier to disassemble the arms from thebridge to allow thorough cleaning of the bridge and other supportcomponents. They also help prevent actions by the user contrary toinstructions that could increase the risk of breakage of the foreheadsupport.

While several improvements have been discussed above, it is contemplatedthat an improved forehead support according to the present inventionneed not utilize all such improvements but can utilize one or more ofsuch improvements in various combinations.

It is to be understood that while the invention has been described abovein conjunction with preferred specific embodiments, the description andexamples are intended to illustrate and not limit the scope of theinvention.

1-42. (canceled)
 43. A respiratory mask with a coupling structure, comprising: a first arm and a second arm each having a proximal end and a distal end, wherein: the arms are positioned to be opposed to one another and are resiliently flexible into a common space upon compression, one of the arms includes an upper mating portion and the other of the arms includes a lower mating portion, whereby the upper and lower mating portions mate upon full compression of arms to prevent or reduce torsion between the arms relative to one another and separate upon release of the arms.
 44. The respiratory mask according to claim 43, wherein at least one of the upper and lower mating portions includes a chevron-shaped slot and a chevron-shaped projection.
 45. A forehead support constructed and arranged to be connected to and support a respiratory mask, comprising: a bridge constructed and arranged to engage a forehead of a user; a first arm having a bridge end and a mask end; and a second arm having a bridge end and a mask end, wherein each of the first and second arms includes an extending portion defining upper and lower flange portions each having a proximal end, a distal end and a central portion, wherein a width of each flange portion along the proximal and central portions is substantially wider than a width of the distal end, and wherein the width of each flange portion is greater than a corresponding thickness of the flange portion in the proximal and central portions.
 46. The forehead support according to claim 45, wherein each of the upper and lower flange portions includes a generally oval depression.
 47. A forehead support constructed and arranged to be connected to and support a respiratory mask, comprising: a bridge constructed and arranged to engage a forehead of a user; a first arm having a bridge end and a mask end; and a second arm having a bridge end and a mask end, wherein each of the first and second arms defines upper and lower arm portions, wherein each of the upper and lower arm portions is tapered down from a proximal end to a distal end thereof.
 48. The forehead support according to claim 47, wherein a space is provided between the upper and lower arm portions, the space having a generally trapezoidal shape. 